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Pumps Valves Service
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KSB SuPremE®: the world‘s
most efficient magnet-less pump motor
02
Introduction
Saving energy has never been so easy
The clever interaction of the five modules of FluidFuture®, KSB‘s energy efficiency concept,
results in the highest possible efficiency of a pump system. Following the introduction of KSB‘s
SuPremE® IE4* motors, FluidFuture® now features a new generation of motors that enable you
to run your system more leanly than with any other pump motor.
FluidFuture®: five modules for greater efficiency
Perfect combination
KSB uses the FluidFuture energy efficiency concept to assess
Combining high-efficiency components reduces energy
the entire hydraulic system. The objective: to increase overall
consumption and saves you real money. The interaction of
efficiency. Following a comprehensive system analysis, KSB
KSB SuPremE® IE4* motor, PumpDrive variable speed system
selects high-efficiency pumps, valves and motors to optimise
and PumpMeter is a case in point. While the operating pressure
the system and ensure maximum efficiency with demand-driven
is continually measured by the PumpMeter intelligent pressure
operation. This means maximum energy savings for you.
sensor, PumpDrive ensures it is adjusted to the actual demand.
®
Especially in the low-flow range, this plays an important role.
It also reduces energy costs and loads on the components. The
savings achieved are further maximised by the exceptional
efficiency of the KSB SuPremE® IE4* motor.
03
System Analysis According to FluidFuture®
Energy-efficient drives for every need
High-efficiency drives form an integral part of the system and
requirements of the field of application, legal guideline require-
are therefore a prime target when it comes to ensuring energy-
ments, annual operating hours and the energy price, this profile
efficient operation. This is why it is essential that the right motor
establishes the basis for realising the optimal drive solution –
is selected for the job. To this end, a load profile is established
which comes from KSB, the only provider to offer an end-to-end
by correlating the data from SES System Efficiency Service , or
range of products and equipment that covers every requirement
operating data is recorded by PumpMeter. Together with the
and demand.
®
KSB SuPremE® IE4* motor
The world‘s most efficient pump motor deserves to be called ‘low-energy drive’.
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Energy savings of 70 percent and more: The efficiency
IE4* motor does not incorporate magnetic materials
gain of up to 60 % due to speed control is increased
even further by an energy saving of up to 30 % in the
or increased levels of copper.
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Far ahead of its time: The IE4 motor (as per IEC (CD)
60034-30 Ed. 2) already exceeds the requirements of
Sustainable: Unlike permanent-magnet synchronous
motors and asynchronous motors, the KSB SuPremE
life of the bearings ensure reliable operation.
■■
Compatible: Wherever there is room for an IE2 asynchronous motor, a KSB SuPremE® IE4* motor can also
the European ErP 2017 regulations.
■■
Robust: Non-critical, durable materials as well as the
fully matured reluctance principle and the high service
motor alone.
be installed to get the work done efficiently.
®
*IE4 to IEC (CD) 60034-30 Ed.2
Energy Diet
Energy efficiency: experience
the future today
The energy diet based on the KSB SuPremE® IE4* motor has an immediate
effect on your energy bills. The synchronous reluctance motor is operated
at variable speed and achieves uniquely stable and high efficiency gains
in all load ranges.
Analyses of existing pump systems have shown that most
electric motors are not run at their rated load point, but mainly
at part load. In Europe, motors are normally operated at no
more than 60 % of their rated load. The efficiency regulations
for electric motors initiated by legislators all focus on operation
7.5 kW ASM IE2, 1,420 rpm
load – but above all with its high efficiency across the entire
45
part-load range – the KSB SuPremE IE4* motor stands out
40
as the lean alternative drive for the future.
35
®
95
90
30
85
25
The diagram shows the efficiency curve plotted over
the load of a 7.5 kW, 1500 rpm SuPremE® IE4* motor in
comparison to a 2-pole IE3 asynchronous motor. Load
Torque in Nm
20
Motor efficiency in %
at the rated load point. With its super premium efficiency at full
80
15
10
75
5
0
profile to “Blue Angel“ requirements.
800 900 1,000 1,100 1,200 1,300 1,400 1,500
Speed in rpm
70
Unparallelled potential savings due to extremely
45
high efficiency – especially in the part-load range.
40
95
90
35
30
90%
20
Torque in Nm
60%
50%
40%
20%
10%
10
75
5
0
KSB SuPremE IE4* motor
®
IE3 asynchronous motor, 50 Hz (2-pole)
80
15
800 900 1,000 1,100 1,200 1,300 1,400 1,500
Speed in rpm
7.5 kW KSB SuPremE®, 1,500 rpm
45
95
40
44%
90
35
35%
30
85
25
20
6%
50%
75%
100%
Source: Dipl.-Ing. M. Wiele, Prof. Prof. h. c. mult. Dr.-Ing. Peter F. Brosch,
Hochschule Hannover, University of Applied Sciences and Arts, Faculty I,
Drives and Automation Technology
Load
Torque in Nm
15%
25%
70
80
15
10
75
5
0
800 900 1,000 1,100 1,200 1,300 1,400 1,500
Speed in rpm
Measured data by Prof. Edgar Stein,
Kaiserslautern University of Applied Sciences, 2011
70
Motor efficiency in %
Efficiency
70%
30%
85
25
80%
Motor efficiency in %
7.5 kW ASM IE3, 1,450 rpm
Distribution of operating
hours in %
04
05
Seizing your individual savings potential in three steps
The KSB SuPremE® IE4* motor was specifically designed to
considerably reduce energy costs. Exactly how much energy
can be saved is computed by the KSB efficiency calculator,
which can be downloaded as an app or used online at
www.none-more-efficient.com.
More efficient than required by ErP regulations
To reduce global power consumption in the
long term, ErP regulations stipulate mandatory
minimum efficiency levels for products that
require a large amount of electrical energy,
since this is where the most savings can be
realised. Drives must also meet the defined
requirements, however, which will continue to
become more stringent as we approach 2017.
It is in this context that the KSB SuPremE® IE4*
motor emerges as the perfect solution for futureoriented systems. After all, the highly efficient
drive already exceeds the statutory requirements
set forth by the 2017 ErP regulations.
*IE4 to IEC (CD) 60034-30 Ed.2
Efficiency calculator
app for Android
smartphones
Efficiency calculator
app for iPhones
06
Technology
The drive solution of the future
The KSB SuPremE® IE4* motor heralds in a new era for pump motors as the main
benefit associated with the DOL starting routine employed by today‘s dominant
asynchronous motors will continue to lose value and importance in the future.
Just like the KSB SuPremE® IE4* motor, these units will also be increasingly
equipped with a speed control system. It is exactly in this actively controlled mode,
however, that the KSB SuPremE® IE4* motor unfolds its full potential by making
every application fit for the future.
The KSB SuPremE® IE4* motor paves the way
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No DOL starting – no unnecessary losses
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Every bit as robust as asynchronous motors
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Rotor laminations geometry for quiet operation
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Losses associated with the speed control system required are marginal
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Easy maintenance because no magnets are used
Variable load profile
Integration of a speed control system
DOL starting is not required
07
No unnecessary losses attributed to DOL starting
Robust for future applications
The success of the asynchronous motor largely has to do
Asynchronous motors have the reputation of being very robust.
with its DOL starting capability. This benefit also presents a
The same can also be said of the KSB SuPremE® IE4* motor,
drawback, however, because DOL starting leads to unnecessary
whose probability of failure is reduced thanks to the omission
losses caused by rotor current as evidenced in the slip that
of sensors, while the lower temperature of the rotor extends the
occurs at this time. Asynchronous motors will be increasingly
service life of the bearings. The KSB SuPremE® IE4* motor also
fitted with a speed control system in recognition of the fact
incorporates only non-critical and durable materials to ensure
that maximum flow rate conditions are not always required. In
smooth operation for many years at a time.
these scenarios, DOL starting is not necessary. There is a better
alternative to this combination setup with a speed control system, however – the synchronous motor. Although synchronous
motors cannot start up without a frequency inverter, they
achieve considerably higher levels of efficiency during
operation as no current is sent to the rotor.
Low-noise operation
One of the ways in which conventional synchronous motors
differ from synchronous reluctance motors such as the KSB
SuPremE® IE4* motor is the special cut of the laminated rotor
core. Formally known as US patent 5.818.140, the invention
refers to a rotor geometry with flux-conducting and flux-blocking
segments that ensure smooth operation. This geometry provides
for an extremely low level of torque ripple (1 to 2 %) that, in
turn, keeps operating noise to a minimum.
KSB SuPremE®: the world‘s most efficient pump motor
*IE4 to IEC (CD) 60034-30 Ed.2
Eco-balance
One step ahead – including when it
comes to resource efficiency
KSB SuPremE® IE4* motors impress with their exceptional overall eco-balance
by not only achieving considerable energy savings, but also contributing to
a healthier environment as the motors incorporate zero magnetic materials
made from rare earths.
Using critical materials is a thing of the past
Many modern technologies are almost impossible to realise
without using rare earths. The problem with this approach is of
course the fact that mining and processing the metals required
can severely impact the environment. Further adding to this is
the monopoly-like situation that prevails in the global market
as China has for years been the largest exporter of rare earth
elements and therefore also establishes market prices.
In developing the KSB SuPremE® IE4* motor, it became very
clear that avoiding the use of these elements was an absolute
must. The solution was to leverage the synchronous reluctance
principle so that the highly efficient drive could also meet IE4
efficiency class requirements without the need for magnets. As
a result, KSB can manufacture its SuPremE motors independ
ently of global market events while at the same time keeping
the environmental impact to a minimum. An independent
PLCA study has confirmed this.
Sustainable, magnet-less design principle
KSB SuPremE® IE4* motors use no magnetic materials or
increased levels of copper, making their design much more
sustainable than that of permanent-magnet synchronous motors
and asynchronous motors.
400
350
CO2 equivalent in kg
08
300
272.3
236.4
250
222
200
150
100
50
0
ASM IE3
PMSM IE4
KSB SuPremE® IE4*
7.5 kW, 2-pole, 1,500 rpm
*IE4 to IEC (CD) 60034-30 Ed.2
In fact, the total environmental footprint of
manufacturing synchronous reluctance motors is
6 percent lower than that of permanent-magnet
synchronous motors, despite the higher output
per size of the latter, as a result of no magnetic
materials being used.
09
Reference Projects
10
The energy diet works
By combining the FluidFuture® energy efficiency concept with the KSB SuPremE® IE4* motor,
KSB has already been able to sustainably improve the operating efficiency of numerous plants.
Heidelberger Druckmaschinen AG
90 % energy savings
Application:
Cooling lubricant circuit of grinding machines with four fixed speed pumps
with motor ratings of 37 kW each
Measure taken:
Replacement of the pumps in conjunction with variable speed, high-efficiency drives
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3 x Etanorm G065-200 PD
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3x PumpDrive MM variable speed system
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3x characteristic curve control unit (PumpMeter)
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3x KSB SuPremE® IE4* motor (22 kW)
All Etanorm pumps feature the PumpDrive
variable speed system.
Result:
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Energy savings of approximately 90 %
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Payback period of just 1.6 years
Each pump is designed for a flow rate of 100 m3/h.
Uwe Ricker, Heidelberger Druckmaschinen AG:
„Astounding efficiency: 90 % energy savings with our cooling
lubricant pumps.“
11
Miele & Cie. KG
40 % less energy required
Application:
Commissioning a new system for centralised cooling water supply
Measure taken:
Use of 2 high-efficiency refrigeration units in combination with:
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Etaline PumpDrive employed as dual-pump sets
11x Etaline GN and 7x Etanorm G pumps – each fitted with PumpMeter
and PumpDrive
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2x high-efficiency KSB SuPremE® IE4* motors
The PumpMeters automatically identify potential savings.
Result:
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40 % less energy required for refrigeration
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Annual reduction of CO2 emissions: 400 tonnes
2 Etanorm PumpDrive pumps for continuous
operation with high-efficiency KSB SuPremE®
IE4* motors
Continental ContiTech Vibration Control GmbH
€ 15,700 saved each year
Application:
Closed-circuit cooling system used for air conditioning and cooling of production facilities
Measure taken:
Replacement of one of the centrifugal pumps installed in the facilities with a
speed-controlled KSB system comprising
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Etabloc pump (single-stage)
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18.5 kW synchronous motor (KSB SuPremE® with PumpDrive S MM, size C)
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PumpDrive speed control system
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Characteristic curve control unit (PumpMeter)
Result:
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Energy savings: approx. 371 kWh/d ➞ € 15,700 p.a.
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Reduction of 1,900 tonnes of CO2 p.a ➞ 74.7 percent
For more information visit
*IE4 to IEC (CD) 60034-30 Ed.2
www.ksb.com/fluidfuture-en/references/
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4075.021/03-EN/01.15 / © KSB Aktiengesellschaft 2015 · Subject to technical modification without prior notice.
Technology that makes its mark